Gusset block construction

ABSTRACT

Gusset Block Construction deals with a block that is cored from all sides. The blocks are cubes and elongated cubes with a pyramid or elongated pyramid shaped cavity on each side resulting in a block in which each of the twelve edges is central on a gusset shape extending from said edge to the central axis of the block. With the use of a second octahedron block that fits within the pyramid shaped cavities a wall that requires no fastening can be built by placing octahedrons in the top cavities of a layer of blocks and placing another layer of blocks on it. These blocks will be able to come apart at the joints during an earthquake without completely disassembling and can return to original position when the earthquake stops. They can be molded in a two piece split mold and are scaleable; tapered piers could be made.

CROSS REFERENCE TO RELATED APPLICATIONS

-   Provisional Patent Application No. 61/465,026     -   Filing Date: Mar. 14, 2011     -   Name of Applicant: Thomas Phillips     -   Title of Invention: Construction Block with Feature for         Earthquake Survival -   Utility Patent Application No. 12/655,690     -   Filing Date: Jan. 6, 2010     -   Name of Applicant: Thomas Phillips     -   Title of Invention: Gusset Plate Construction

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

NOT APPLICABLE

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

NOT APPLICABLE

BACKGROUND OF THE INVENTION

Construction Blocks have been around a long time; they are generally made of concrete and have vertical holes extruded through them. Another common Construction Block is the brick which may or may not have holes extruded through. In general coring of these blocks to conserve material is through the top and bottom; to core the front or back face would require a side core in the mold. Each of these is usually assembled with mortar which requires considerable expertise, time, and labor, to serve as an adhesive and spacer at the joints. This results in a one piece wall which if cracked in an earthquake or other event may fall apart or be in danger of falling apart without major repair.

BRIEF SUMMARY OF THE INVENTION

Gusset Block Construction deals with a construction block that is cored from all sides as opposed to the top and bottom. To be able to do this the block is shaped such that it could be molded in 2 plate split mold that has an axis of movement that is at 45 degrees from the 3 faces of a given corner of the block. The construction blocks are cubes or elongated cubes with pyramid, or elongated pyramid, shaped cavities on each of the 6 sides resulting in a block in which each of the 12 edges is central on a gusset extending from said edge to the center or central axis of the block. With the use of a second octahedron block that fits in the pyramid shaped cavities a wall that requires no fastening can be built by placing octahedrons in the top cavities of a layer of blocks and placing another layer of blocks on it. Further with the use of large tapered blocks and the use of the octahedron block that fits within the pyramid cavity large piers for bridges and other platforms can be built. These assemblies will be able to part at the joints during an earthquake without disassembling completely and if they do come apart may in many cases remain intact and be put back together again. In addition coring the face and back of the block provides a place to nail or screw a block to a block beneath it if desired.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 shows a basic cube shaped Gusset Construction Block in the front view of the plane it is molded in.

FIG. 2 shows a basic cube shaped Gusset Construction Block as seen from any of 6 equal sides.

FIG. 3 shows a basic cube shaped Gusset Construction Block with thicker walls and a provision for alignment shown in the front view of the plane it is molded in.

FIG. 4 is a top view of the Gusset Construction Block shown in FIG. 3.

FIG. 5 is a section view taken from FIG. 4.

FIG. 6 is shows an elongated cube shaped Gusset Construction Block shown in the front view of the plane it is molded in.

FIG. 7 is a top view of the Gusset Construction Block shown in FIG. 6.

FIG. 8 is a section view taken from FIG. 7

FIG. 9 is an assembly view of a wall made with Gusset Construction Blocks shown in FIG. 3 and FIG. 6; shown in the front view of the plane they were molded in.

FIG. 10 is a top view of FIG. 9.

FIG. 11 is a section view taken from FIG. 10.

FIG. 12 is an orthogonal view of an octahedral shaped block with 2 of 8 faces, 3 shown.

FIG. 13 is a top view of the octahedral shaped block shown in FIG. 12.

FIG. 14 is a side view of the octahedral shaped block shown in FIG. 12.

FIG. 15 is an orthogonal view of an ernate octahedral shaped block which is hollow.

FIG. 16 is a top view of the block in FIG. 15.

FIG. 17 is a section from FIG. 16 showing the block to be hollow and open at the top.

FIG. 18 is an orthogonal view of an elongated block with the top shape of two octahedral shaped blocks molded into the top surface taking away the need for the separate octahedral component.

FIG. 19 is a top view of the block shown in FIG. 18.

FIG. 20 is a section through the block in FIG. 19 showing it to be hollow.

FIG. 21 is a view of a solid block with an integral octahedral component shown in the plane it is molded in.

FIG. 22 is a top view of the block in FIG. 21.

FIG. 23 is a section from FIG. 22.

FIG. 24 is a top left orthogonal view of two elongated blocks with molded holes for fastening them together.

FIG. 25 is a bottom left orthogonal view of the two elongated blocks with molded holes from FIG. 24.

FIG. 26 is an orthogonal view of pier or post made of 4 tapered blocks.

FIG. 27 is a top view of the pier or post shown in FIG. 24

FIG. 28 is a section from FIG. 27.

FIG. 29 is an orthogonal view of a frustum of a cone shaped block.

FIG. 30 is a hollow part shaped to fit the top cavity of the frustum of a cone shaped block shown in FIG. 29 and the bottom cavity of a block placed on top of it.

FIG. 31 is a top view of two frustum of cones and a hollow part in assembly.

FIG. 32 is a section from FIG. 31.

DESCRIPTION OF INVENTION

The Gusset Block Construction system invention is comprised of a cube shaped block cored from all 6 sides; a second block that is the same as the first excepting that it is elongated by a factor of 2, and a 3rd octahedral block that fits within the cored out areas of two cubes stacked together holding them in alignment. In assembly for one block to move horizontally with respect to another it will be required to move apart from it also; Further, in this construction block system, blocks can move vertically and are expected to do so in the event of an earthquake or other forces that encourage separation of blocks, therefore gravity holds the faces of the blocks together and in alignment in the planes perpendicular to earth as well as the plane horizontal to earth, for purposes of this specification, a level floor or footing. The blocks will move apart when forced but will come back together by themselves due to physical configuration and gravity.

On each face of the first said block, the cube shaped block, a square is centrally drawn and this square forms the base of a pyramid facing into the cube from which material is removed. The angle between opposing faces of the said pyramid is to be greater than 90 degrees, the reason being that a two piece split mold can be used to mold the block if the mold movement axis is determined by a line drawn from one corner of the cube and central to the 3 faces of the cube intersecting at said corner, and further to serve as a ramp as will be explained further into this specification. FIG. 1 shows such a cube as molded, and FIG. 2 shows the face of the cube as seen from any of the 6 sides. Note that the axis of movement for the mold halves derived for this block remains the same for the second elongated block yet to be described.

The blocks shown to this point have been thin and might be made of injection molded plastic. They might be suitable for walls for many structures with initial cost of manufacture and assembly being a major consideration and structural integrity lesser so; toys for example or temporary office walls. In the remaining portion of this specification thicker walled blocks will be shown; the basic concepts will remain the same.

FIG. 3 is a cube shaped block with a thicker wall and with pyramid shaped projections 1, on it's top face, shown in the plane of molding. FIG. 4 is a view of the top face of the cube shaped block in FIG. 3 and FIG. 5 is a section view of FIG. 4 showing indentations 2, to mate with the projections 1. Note that the angle between the opposing faces, referring to FIG. 3, on pyramid shaped projection 1, is greater than 90 degrees for purposes of draft in molding and also to serve as a ramp for a top block to rise on a block beneath it in the event of horizontal forces such as in an earthquake or a bump from a vehicle.

When a cube shaped block is placed on a level floor on earth and a second cube shaped block stacked on top of it with said projections in said indentations and then a force applied horizontally to said top block, said top block will rise a distance and if said distance is less than the height of said projections then when said force is removed said top block will slide back to its previous position on said bottom block due to gravitational force.

FIG. 6 is the same block as that in FIG. 3 with its length multiplied by a factor of two making the block 2 cube lengths long and one cube length high and wide and with the pattern of projections and indentations mirrored on a vertical plane through the center of the block shown FIG. 7 top view. As previously noted the axis of movement for the mold halves remains the same as was derived from the block shown in FIG. 3. From an outside corner a line is drawn central to the planes of the 3 faces of the block and this line could serve as the axis of movement to mold the block with a 2 plate mold.

FIG. 7 is a top view of the block in FIG. 6, and FIG. 8 is a section from FIG. 7. Referring to FIG. 3 a pattern of 4 projections, 1, is shown, referring back to FIG. 7, two such patterns exist and it is intended to be obvious that two cube shaped blocks as shown in FIG. 3 could be placed on top of one elongated block as shown in FIG. 8 and that referring to FIGS. 5 and 7 that items 1 and 2 would fit together. Further it seems obvious that the same patterns could be used on other sides; the ends for instance or even the front and back which would perhaps serve no other purpose than to allow assembly using the front face as the top or bottom face.

FIG. 9 is a right angle assembly of the first block variation shown in FIG. 3 and the second block variation shown in FIG. 6. FIG. 10 is a top view of FIG. 9, and FIG. 11 is the section denoted in FIG. 10.

In the interest of clarity the first paragraph will be repeated. “The Gusset Block Construction system invention is comprised of a cube shaped block cored from all 6 sides; a second block that is the same as the first excepting that it is elongated by a factor of 2, and a 3rd octahedral block that fits within the cored out areas of two cubes stacked together holding them in alignment.”

The said third octahedral block is an 8 sided block sized to fit the inside of the bottom cored out area of a top block and the inside of the top cored out area of a bottom block in an assembly of a top block, an octahedral block, and a bottom block. FIG. 12 is an injection molded octahedron with the faces, 3, cored to conserve material used and maintain good molding practice. FIG. 13 is a top view of this part and FIG. 14 a side view of the same part. In this block all 8 faces are identical.

A second octahedral block is shown in FIG. 15; it is hollow and has an open top to allow for adding sand, water or other material for weight or other properties desired. FIG. 16 is a top view of the octahedral block shown in FIG. 15, and FIG. 17 is a section taken from FIG. 16.

FIG. 18 is an octahedral view of an elongated block with the top pyramid shaped cores removed and replaced by pyramid shaped projections. FIG. 19 is a top view of the elongated block shown in FIG. 18 and FIG. 20 is a section from FIG. 19. Note in FIG. 18 that the top has projecting pyramids as opposed to indentations. Further note in FIG. 20 that the block is hollow; a block such as this could be blow molded or rotationally molded or molded of structural foam with the hollow area being foam.

FIG. 21 is an orthogonal view of an elongated cube shaped block with a configuration on the top surface that will serve as the top surface of a pyramid shaped projection to mate with the bottom pyramid shaped cavity of a block placed on top of it that is cored within the top pyramid shape; to do this two of the pyramid faces have been removed and a gusset 6 serves to provide a pyramid shaped projection surface at the corner where the two removed pyramid faces would have joined. FIG. 22 is a top view of this elongated block and FIG. 23 is a section through FIG. 22. As can be seen in FIG. 23 some additional material would be required to mold this configuration.

FIG. 24 and FIG. 25 are octahedral views of two elongated blocks with holes molded into them; when a fastener is inserted into the holes the blocks are forced into alignment. A hole 4, and a hole 5, referring to FIG. 24 and FIG. 25, can be molded into the block with negligible increase in cost as they are in the axis of mold plate movement. A block of this type might be molded of structural foam or pressed wood composite; or concrete. Further, material permitting, nails can be driven through the surface above the item 5 location, through the block and into the block beneath.

Finally, a last variation of the Construction Block System is the tapered block. These would likely be large and used for piers or posts to support platforms or bridgework. The examples shown will be square and round at the base and tapered from all sides equally but it need not be limited to that; each of these could be elongated as with the elongated block previously shown and also could be tapered on one, two or 3 sides.

Item 6, FIG. 26 is a tapered block 1000 units square at the bottom 1000 units high and 900 units square at the top. The ratio of the top and bottom squares being 900/1000 it follows that if a second block is made 90 percent scale of the first tapered block that the bottom of it will fit the top of the first said tapered block and that if a third block is made 90 percent scale of the second that the bottom of it will fit the top of the second. Further the same holds true for the octahedron parts and or pyramid projections and indentations.

This block could be molded with an axis of mold movement defined by a line from a bottom outside corner that is at 45 degrees to 3 planes intersecting at said corner, these 3 planes being defined as a bottom plane that mates with the bottom of said tapered block and two vertical planes that are perpendicular to said bottom plane and to each other.

FIG. 27 is a top view of the assembly in FIG. 26 and FIG. 28 is a section from FIG. 27 showing hollow octahedral parts between individual blocks. Note that a hole is present on the top of each octahedral part so that sand, water, concrete or other material may be put in. It is possible to use the octahedral parts as containers if an inlet and outlet are provided; one hole could serve for both.

FIG. 29 is an orthogonal view of a round version of the block shown in FIG. 26. It could be molded in a two piece split mold with and axis of movement determined by a line drawn from the bottom center of a gusset, 7 to top center of the opposing gusset 8. Note that this is essentially the same as used with the square base tapered block. The octahedral insert used in flat plane blocks described previously is replaced by a conical insert and an example is shown in FIG. 30. FIG. 31 is a top view of the conical frustum shown in FIG. 29 with the part shown in FIG. 30 placed in the cavity on the top face; FIG. 32 is a section from FIG. 31. 

1. a block set used to build walls comprised of a first group of molded cube shaped blocks comprised of two intersecting circular arrays of a pyramid shaped cup; said pyramid shaped cup having an outside base that is square and an angle between the base and each side of 45 degrees; further within this shape sharing the same base, orientation, and central to it, a second pyramid shape having a base that is square and an angle between said base and each side less than 45 degrees from which material is removed; this creating a pyramid shaped cup; and further a first said array of said pyramid shaped cup is defined by a first axis parallel to an edge of said base of said pyramid shaped cup and passing through the apex of said pyramid shaped cup; said first array is four pyramid shaped cups in a circular array rotated around said first axis 90 degrees apart, and further said second array of said pyramid shaped cup is defined by a second axis which is parallel to said base of said pyramid shaped cup and perpendicular to said first axis and passing through the apex of said pyramid shaped cup, said second array is two pyramid shaped cups in a circular array around said second axis 180 degrees apart and rotated 90 degrees on said second axis, and further the outside angular faces of all pyramids being joined with bases exposed forms a cube shaped block with a gusset shape extending from each outside edge to the central axis and further this cube shaped block could likely, but not necessarily, be molded in a two piece split mold with an axis of mold opening defined by a line drawn from an outside corner that is at 45 degrees to each of the intersecting faces at said corner of origin; and further comprised of second group of molded cube shaped blocks that is identical to the first excepting that it is elongated in one plane by a factor of two, the inverted pyramid shape on two opposing ends remaining the same but the inverted pyramid shape on four faces and the associated gusset shapes being elongated; and comprised of a third group of octahedron shaped blocks in which the top four faces and the bottom four faces of said blocks can mate with the four faces of the said pyramid shape removed from the said cube shaped blocks; such that when one cube shaped block is placed on top of another with an octahedron shaped block in between the two said cubes will be aligned on their six external faces; and further when three elongated cubes are laid end to end on a level surface and at one end of this assembly three additional elongated cubes are laid end to end on said same level surface perpendicular horizontally an L shaped wall one cube high will result and further, on the top of this horizontal L shaped assembly 12 octahedron parts are placed and further, a cube shaped block is placed on top of this assembly at both ends of said L shape followed by placing 5 elongated cube shaped blocks in between then an L shaped wall assembly 2 cubes high will have been constructed with faces aligned and if a horizontal force is applied to a said top block and it moves horizontally then it will also move a distance vertically and if this distance is less than the height of the portion of said octahedron protruding from said bottom block then when said force is removed then said top block will slide back into alignment on said bottom block; and further this wall may be extended in length width and height indefinitely and further said wall can have additional walls added at 90 degrees as was the said second group of three blocks that formed an L shape and further in this block set gravity can hold the blocks together and in alignment with the planes perpendicular to earth as well as the plane horizontal to earth or level and should they part a distance in an earthquake or from any cause they may come back into alignment and remain functional.
 2. The block set in claim 1 in which the said octahedrons are hollow and have an open end at the top for sand, water or other material to be added.
 3. The block set in claim 1 in which protrusions are molded onto one face or faces and indentations into the opposing face or faces of blocks such that when they are stacked with faces aligned as in claim 1 said protrusions fit into said indentations and said blocks are aligned with or without the insertion of the said octahedron components; further said protrusions and indentations are likely pyramid shaped, but conical or some other shape is possible, in order to serve as a ramp and also so that they can be molded without a side core using normal draft angles and further that when one block is placed on top of another and said protrusions are within said indentations, and a horizontal force applied to said top block, moving it horizontally with respect to said bottom block, said top block will also move vertically a distance and if this distance does not exceed the height of said protrusions then when said force is removed said top block will slide back to its original position with the protrusions aligned within the indentations and should they part a distance in an earthquake or from any cause they may come back into alignment and remain functional.
 4. The block set in claim 1 in which a first set of holes are molded through the front and back faces of a block external to the pyramid core removed, near the bottom, with a center axis parallel to the axis of mold movement and a second set of holes that are not through holes but to a given depth molded into the top face in alignment with said first holes such that when screws or other fasteners are inserted through said first holes in a top block and into said second holes in a block beneath it the two blocks will be aligned.
 5. The block set in claim 1 in which a block can be attached to another block beneath it by driving a nail through the inside surface of the lower gusset shape and through it and into the upper gusset shape on the block beneath it such attachment also being possible on the ends.
 6. a block set used to build piers or posts comprised of a first frustum of a pyramid shaped block comprised of two intersecting circular arrays of a pyramid shaped cup, said pyramid shaped cup having an outside base that is square and an angle between the base and each side of 45 degrees; further sharing the same base and central to it a second pyramid shape having a base that is square and an angle between the base and each side less than 45 degrees from which material is removed; this creating a pyramid shaped cup; and further a first said array of said pyramid shaped cup is defined by a first axis parallel to an edge of said base of said pyramid shaped cup and passing through the apex of said pyramid shaped cup; said first array is four pyramid shaped cups in a circular array around said first axis 90 degrees apart, and further said second array of said pyramid shaped cup is defined by a second axis which is parallel to the base of said pyramid shaped cup and perpendicular to said first axis and passing through the apex of said first pyramid shaped cup, said second array is two pyramid shaped cups in a circular array around said second axis 180 degrees apart and rotated 90 degrees on said second axis, and further the outside angular faces of all pyramids being joined with bases exposed forms a cube shaped block with a gusset shape extending from each outside edge to the central axis and further this cube shaped block can be set on a level surface on earth and given a top and bottom and further the sides may be tapered by decreasing the scale of the top pyramid shapes making it X percentage of the bottom pyramid shapes and removing material from the vertical faces connecting the top and bottom edges with four angled planes forming a block with the shape of a frustum of a pyramid; and further comprised of an octahedron part with a top and bottom each having four faces; said four faces of size and shape to mate with the four faces of the pyramid shaped part removed from the top face of said frustum of a pyramid and further comprised of a second molded frustum of a pyramid shaped block that is identical to the first but is scaled to the said X percentage of said first frustum of a pyramid block that the top face of said frustum of a pyramid is to the bottom face of said frustum of a pyramid; and further said first frustum of a pyramid being placed on level earth or a footing and anchored, the said octahedron part placed on top of it and second frustum of a pyramid on top of that an assembly is made and further if a horizontal force is applied to said top frustum of a pyramid, moving it horizontally that it will also move a distance vertically and if such distance is less than the height of said octahedron part protruding from said first block then when said force is removed said frustum of a pyramid block will move back into alignment with said first frustum of a pyramid block and for each additional level added the next frustum of a pyramid block and next octahedral block are made the same X percentage scale of the existing top frustum of a pyramid that the second was of the first.
 7. The block set in claim 6 in which the frustum of a pyramid shape is elongated in one axis such that the base and top are not square but rectangular.
 8. The block set in claim 6 in which protrusions are molded onto the top or bottom face and indentations into the opposing face such that when they are stacked as in claim 6 said protrusions fit within said indentations and they are aligned with or without the insertion of the said octahedron components; further said protrusions and indentations are likely pyramid shaped, but conical or some other shape is possible, in order to serve as a ramp and also so that they can be molded without a side core using normal draft angles and further that when one block is placed on top of another and said protrusions are within said indentations and when a horizontal force is applied to said top block moving it horizontally with respect to said bottom block said top block will also move vertically a distance and if this distance does not exceed the height of said protrusions then when said force is removed said top block will slide back to its original position with protrusions aligned within indentations.
 9. The block set in claim 6 in which a first set of holes are molded through the front and back gusset faces external to the pyramid core removed near the bottom, with a center axis parallel to the axis of mold movement and a second set of holes that are not through holes but to a given depth molded into the top face in alignment with said first holes such that when screws or other fasteners are inserted through said first holes in a top block and screwed into said second holes in a block beneath it the two blocks will be aligned.
 10. The block set in claim 6 in which gravity holds the blocks together and in alignment with the planes perpendicular to earth as well as the plane horizontal to earth or level and should they part a distance in an earthquake or from any cause they may come back into alignment and remain functional.
 11. A block set that could be used to build piers or posts with a bottom that sets on earth or a footing on earth and a top that is above earth a distance determined by the height of a given block or blocks, comprised of a first part, which is a frustum of a cone shape molded block; said block having a large diameter face at one end and a smaller diameter face at the other end; and further said smaller diameter being X percent of said larger diameter and further being cored at each end by an inverted right circular cone with a perimeter at the face concentric with the perimeter of the outside edge of the face and an angle at its vertex greater than 90 degrees; further said frustum of a cone shape molded block being such that it can be molded in a 2 piece split mold with an axis of movement defined by a line passing through the intersection of 3 planes; the first plane defined as the larger diameter face of the frustum of a cone, the second plane perpendicular to it and tangent to the edge of the larger diameter face, and the third plane passing through said point of tangency and lying on the central axis of said frustum of a cone; said line at 45 degrees with respect to said tangent plane and passing through the intersection of the three said planes and lying on the plane passing through the said axis of said frustum of a cone and passing through said frustum of a cone, and further, said shape may be cored on the external length to create a substantially equal wall thickness resulting in an external shape of two cones joined near their apex with open ends facing out and further to this shape 4 equally spaced ribs or gussets may be added 2 of which are centered on the plane upon which the axis of mold plate movement lies; and further comprised of a second part with the shape of two cones joined at the base and said cones having a diameter that matches the diameter of said inverted right circular cone on the top surface of said block and further an angle at the vertex that matches that of the vertex of the cone portion removed from the top face of said first part, and further when said second part is placed on top of said first part and a third part comprised of a block identical in shape but scaled to said X percent of said first part is placed on top of said second part then two said conical frustum blocks will be assembled with all parts aligned and if a horizontal force moves said third part and or said second part then said third part will rise a distance and if said distance is less than the height of the protrusion of said second part above said first part then when said horizontal force is removed said third part will slide back into alignment with said first part and further for each additional level added the parts are identical in shape but scaled the same X percentage of the top parts in place that the top diameter was of the bottom diameter.
 12. The block set in claim 11 in which said second part with the shape of two cones joined at the base is a hollow part open at the top into which water sand or other material may be placed for weight or other properties and further which may be used for storage; as a tank.
 13. The block set in claim 11 in which said cone shaped frustum is elongated in one axis such that when it is viewed from the top or bottom a half circle is seen at each end with straight lines connecting the two halves.
 14. The block set in claim 11 in which a protrusion or protrusions are molded onto one face and an indentation or indentations are molded into the opposing face such that when blocks are stacked with faces aligned as in claim 5, said protrusions fit into said indentations and said blocks are aligned with or without the insertion of said second part and further, said protrusions are likely pyramid shaped, but conical or some other shape is possible, to serve as a ramp and also so that they can be molded without a side core using normal draft angles in a 2 piece split mold, and further when a second block being the same shape but scaled X percent of a first block is placed on top of a first block and faces are aligned and a horizontal force is applied to said second block moving it horizontally then said second block will also move a distance vertically and if said distance is less than the height of said protrusions then when said force is removed said second block will slide back into position on said first block with faces aligned.
 15. The block set in claim 11 in which gravity holds the blocks together and in alignment with the planes perpendicular to earth as well as the plane horizontal to earth or level and should they part a distance in an earthquake or from any cause they may come back into alignment and remain functional. 